Toilet flanges and the mounting thereof

ABSTRACT

An improved flange that provides simple and time saving installation of a toilet fixture. The flange includes an annular ring that defines at least one aperture adapted to receive a connector for attaching the flange to the floor and at least one mounting bolt rigidly and permanently affixed to the annular ring, the mounting bolt extending upwardly from the annular ring and being adapted to pass through at least one mounting aperture of the toilet. The flange is adapted for use in originally attaching the toilet to the floor or in repairing or extending existing flanges. In one embodiment, the flange is used in combination with a one-piece mounting cap that removes the need for separate washers and nuts.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to the field of plumbing and moreparticularly relates to a toilet flange and various embodiments thereofand the mounting of a toilet fixture thereon.

2. Background of the Invention

Numerous efforts have been made to mount toilet fixtures known as“commodes” or “water closets” to a bathroom floor since the advent ofthe modern lavatory. In general, the toilet is mounted over an opening(i.e., drain hole) in a bathroom floor and secured thereto using aflange and a wax seal. The flange is mounted to the bathroom floor inregistry with the drain hole in the floor and one or more mounting boltsare passed through bolt openings in the flange and then throughcorresponding openings in the toilet, and secured thereto using nuts orother fasteners to secure the toilet to the floor about the opening. Inthe past, a pair of bolts have been used in association with, but notrigidly and permanently affixed to, the flange. These bolts are passedthrough openings in the flange body in an upward direction prior to theflange being mounted to the floor using conventional fastening means.The bolts are positioned in an upstanding orientation such that, whenthe toilet is lowered into place over the flange, the bolts will passthrough the corresponding openings in the toilet. However, because allof the products known to the inventor on the market today suffer fromthe disadvantage of having the bolts freely movable related to theflange, one slight shift in the orientation of the bolts will preventthe installer from being able to place the toilet over the flange whilesimultaneously causing the bolts to pass through the openings in thetoilet. Since toilet installations are usually done by one person, thisleads to the extremely frustrating and time consuming situation wherethe installer, after having lifted the heavy toilet and attempted toslowly lower it onto the flange, accidentally bumps one or both of thebolts, causing them to fall out of position. The installer then has toraise the toilet back up and move it to a different location and set itdown on the floor and reorient the bolts. This event can happen over andover again given the modern toilet flange kits employ bolts which arevery easy to move out of the vertical orientation. This situation isfurther exacerbated when installing a toilet in a tight space.

Once the toilet fixture is successfully placed above the mounting boltsand the flange, threaded nuts are typically used to secure the toilettightly to the floor/flange juncture. These nuts are particularlyunsightly. Hence, there have been developed numerous covers and caps tocover the nut, bolt, and washer on either side of the toilet and therebyimprove the aesthetic appearance thereof. However, it is particularlyundesirable to use the caps that are now uniformly available as they canbe easily knocked out of place, work loose essentially on their own overtime, and become lost.

Another frequently encountered problem with in-use toilet flanges isthat they occasionally become broken. Once the flange breaks, the toiletis subject to movement and leakage. Presently, the only ways to remedythis type of situation is to remove the toilet, remove the flange andreplace it with a new flange or to remove the toilet and use a repairflange that requires assembly and separate bolts and nuts. Removal ofthe existing flange can be both difficult and time consuming, as well ascreate collateral problems relative to leakage and the alignment thereofwith the opening in the floor.

Even further, when remodeling a bathroom, it is commonplace to put downnew flooring, e.g. hardwood or tile, and purchase and install a newtoilet fixture. The new flooring prevents the direct installation of thenew toilet fixture to the existing flange due to the increased height ofthe new floor. One remedy to this situation is the current use of anextension flange. The commercially available extension flanges do notinclude rigidly and permanently affixed bolts. Similar to the issuediscussed above with regard to new installation, the installer mustplace the toilet on the bolts without knocking them over. Another remedyis to cut the existing flange out and replace it with a new constructionflange at the correct floor level. Either remedy adds unnecessarily tothe complexity and time consumption associated with the installation.

It is, therefore, an object of this invention to improve the apparatusused to mount a toilet fixture to a bathroom floor.

It is also an object of the present invention to facilitate the simpleand time saving installation of a toilet fixture to a bathroom floor bya single installer.

It is a further object of this invention to provide a toilet mountingflange wherein mounting bolts associated therewith are rigidly andpermanently fixed relative to the flange, without the need for assembly.

It is a still further object of this invention to provide toilet bowlmounting nuts that have a decorative cap integrally formed therewithwithout the need for washers.

It is also an object of this invention to provide a toilet flange whichpermits the easy repair thereof without removal of the broken toiletflange, or the use of separate parts i.e. flange, bolts, washers, andnuts.

It is also an object of the invention to provide a toilet flange whichcan be used to accommodate a new floor.

These and other objects of the invention, along with various features ofnovelty which characterize the invention, are pointed out withparticularity in the claims annexed to and forming a part of thisdisclosure. For a better understanding of the invention, its operatingadvantages and the specific objects attained by its uses, referenceshould be had to the accompanying drawings and description, in whichthere is illustrated multiple embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded elevational view of one embodiment of theone-piece toilet flange and the one-piece toilet bowl mounting cap ofthe present invention being utilized to mount a toilet to a floor.

FIG. 2 is top plan view of the one-piece toilet flange of FIG. 1 shownspaced from a wall.

FIG. 3 is an exploded elevation view of a second embodiment of theinvention in the form of a one-piece toilet repair flange and theone-piece toilet bowl mounting cap being utilized to repair the brokenflange of an existing toilet.

FIG. 4 is a perspective view of the one-piece toilet repair flange ofFIG. 3.

FIG. 5 is an exploded view of a third alternate embodiment of thepresent invention in the form of a one-piece toilet extension flange andthe one-piece toilet bowl mounting cap used to accommodate a rise in thefloor level due to the added thickness of flooring being installed(i.e., tile or hardwood) during a remodeling project.

FIG. 6 is a top plan view of the one-piece toilet extension flange ofFIG. 5.

FIG. 7 is a side plan view of the one-piece toilet bowl mounting cap ofthe present invention.

FIG. 8 is a bottom view of the mounting cap of FIG. 7.

FIG. 9 is a perspective view of the mounting cap of FIG. 7.

DETAILED DESCRIPTION

In view of the foregoing shortcomings inherent in the toilet flanges andmounting hardware presently available on the market and in view of theobjects set forth above, the present invention is directed to aplurality of improved toilet fixture mounting assemblies.

The first such assembly, which is depicted in FIG. 1, is particularlysuited to new construction applications and employs a toilet mountingflange 10 in the form of an annular ring body 11 (best seen in FIG. 2)mounted to a bathroom floor F, generally substantially in registry witha toilet drain D. The flange 10 has rigidly and permanently affixedthereto one or more mounting bolts 12 extending upwardly therefrom. Theflange 10 is secured to the floor F using any suitable mountingfasteners 20, such as mounting screws. A drain spout 16 may beassociated with the flange 10 to assist in the alignment of the flange10 with the toilet drain D and drain hole, although a drain spout 16 isnot considered to be essential to this invention. If the flange 10 ismounted to the floor F, a wax seal 23, as is widely known in the art,may be placed on the flange 10 in registry with the drain hole and thebase 25 of the toilet fixture to be lowered thereupon. The toilet base25 defines one or more apertures 24 therethrough adapted to receive theone or more bolts 12 which are rigidly and permanently affixed to theflange 10. By having the bolts 12 rigidly and permanently affixed to theflange 10, bumping or knocking the bolts 12 while installing the toiletbase 25 to the flange 10 will not cause the bolts 12 to becomedisoriented. Corresponding one-piece toilet bowl mounting caps 21 areemployed to threadingly engage the bolts 12 and sandwich the toilet base25 between the flange body 10, the wax seal 23 and the one-piece toiletbowl mounting caps 21, thereby affixing the toilet base 25 to the floorF. Suitable finishing steps may be employed thereafter, such as caulkingaround the juncture of the toilet base 25 and the floor F, although suchsteps are not considered to be a part of the invention.

The flange 10 employs one or more floor mounting holes 14 peripherallyabout the annular ring body 11 adapted to receive floor mountingfasteners 20 therethrough while attaching the flange 10 to the floor Faround the drain hole. The flange 10 includes two or more indicia suchas alignment lines 15 that can be used to properly align the flange 10,and as a result the toilet base 25, with a wall W. As shown in FIG. 2,during installation, the alignment lines 15 are each equally spaced adistance X from the wall W, ordinarily by using a measuring instrument,and then the floor mounting fasteners 20 are used to secure the flange10 to the floor F.

As most toilet bases 25 currently employ a pair of mounting apertures24, one on either side of the toilet base 25, the preferred embodimentof the invention employs a pair of mounting bolts 12 which arepreferably made of brass, but may be made of nylon, fiberglass,polyvinyl chloride (PVC), or any other material having suitable strengthand durability/corrosion resistance. Each of the bolts 12 is rigidly andpermanently affixed to the flange 10, as by molding together orotherwise firmly and permanently attaching the bolts 12 to the flange10.

In another embodiment, depicted in FIGS. 3 and 4, a repair flange 30 isdisclosed, adapted to be used to cover any existing broken flange. Theflange 30 comprises a thin, annular body 31, preferably made of metal,but may be made of any suitable material, having one or more mountingholes 34 defined by mounting tabs 33 arranged peripherally about theperiphery 31 of the flange 30. In use, when an existing toilet flangebreaks, the toilet is removed. The existing mounting bolts extending upfrom the broken toilet flange are removed and discarded as by slidingbolts out of the keyway in the flange and the repair flange 30 mounteddirectly above the broken flange in registry with the drain hole. Newmounting fasteners 40 are placed through the apertures 34 in themounting tabs 33 and driven into the floor F to securely mount therepair flange 30 thereover. The repair flange 30 incorporates rigidlyand permanently affixed mounting bolts 32 extending upwardly therefromupon which the toilet base 45 can be mounted as described in connectionwith FIGS. 1 and 2. In this way, the problems associated with a brokentoilet flange can be remedied without removing the existing flange, asremoval thereof is often extremely difficult and may result in damage tothe toilet drain which extends into the floor.

Another embodiment of the invention is disclosed in FIGS. 5 and 6 andcomprises a toilet flange 50 adapted to be utilized to bridge the gapbetween a toilet fixture and the floor/toilet drain opening when newflooring has been installed. For example, in a remodel, it is commonplace to install new tile, wood flooring, etc., which raises the levelof the floor relative to the drain opening in the original floor.Because of this, the existing flange is not high enough relative to thenew floor level. To rectify this, the extension flange 50 is employed,which is of a thickness T that is sufficient to substantially match thethickness of the new flooring F¹. The extension flange 50 is mounteddirectly over the existing flange, eliminating the need for anyadditional work preparatory to the installation of the toilet. Theexisting mounting fasteners in the original flange are removed. Ifpossible, the apertures 54 in the extension flange 50 are aligned overthe original holes. If not, the new floor mounting fasteners 60 arepassed through the old flange where necessary. The extension flange 50is mounted directly into the floor and rigidly and permanently affixedmounting bolts 52 extend upwardly there from to which the toilet fixtureis mounted as discussed above.

It is to be understood in connection with this invention that it is aprincipal feature of each embodiment that the mounting bolts be rigidlyand permanently affixed to the flange such that they act as one piecewith the flange and, as a result, the toilet base mounting bolts willremain in their vertical orientation when the flange is mounted to thefloor.

To overcome the disadvantages inherent in using a simple nut to attachto the mounting bolts while mounting the toilet base, the presentinvention also contemplates the use of a one-piece toilet bowl mountingcap 61. The one-piece toilet bowl mounting cap 61 eliminates the needfor separate nuts and washers. The one-piece toilet bowl mounting cap 61defines internal threads 62 adapted to be threadingly engaged toexternal threads on the toilet flange mounting bolts and an integralcovering thereover. The one-piece toilet bowl mounting cap may be madeof polyvinyl chloride (PVC), nylon, fiberglass, or any other moldablematerials. The covering may take any form, for example it may bespherical, square, rectangular, oblong, elliptical, it may have ahexagonally arranged surface adapted to be engaged by a wrench, etc. Inthe embodiment shown in FIGS. 7 through 9, the one-piece toilet bowlmounting cap 61 is formed in an oblong shape which facilitates the handtightening of the cap 61 over the mounting bolt while preventing thepossibility of cracking the toilet base by over tightening. The oblongshape provides the necessary leverage for the installer to tighten thenut to a degree which will cause the toilet to be securely and snugglymounted to the mounting bolt/toilet flange. In addition, the one-pieceembodiment removes the likelihood of the cap being accidentally knockedfrom the bolt. The one-piece toilet bowl mounting cap 61 combination mayfurther eliminate the need to utilize a washer because the contactsurface 66 may serve as a built in washer.

The invention has been shown and described herein in the form ofmultiple embodiments with alternative features. It is to be understood,however, that the invention is not limited to the embodiments disclosedherein, and that the invention is intended to be limited only by thefollowing claims.

1. A flange for mounting a toilet to a surface, the toilet including abase portion defining at least one mounting aperture, the flangecomprising: an annular ring defining at least one aperture adapted toreceive a connector for attaching the flange to the floor; at least onemounting bolt rigidly and permanently affixed to the annular ring, theat least one mounting bolt extending upwardly from the annular ring andbeing adapted to pass through at least one mounting aperture of thetoilet.
 2. The flange of claim 1, wherein the surface is a floorproximate at least one wall of a room, the flange further comprising oneor more alignment indicia disposed on the annular ring to facilitatepositioning of the annular ring such that the toilet is mounted in apredetermined angular orientation relative to the at least one wall. 3.The flange of claim 1, further comprising a drain spout.
 4. The flangeof claim 1, further comprising at least one one-piece toilet bowlmounting cap, the toilet bowl mounting cap including a decorative outersurface and a threaded, recessed inner surface, and adapted to beengaged by the at least one mounting bolt to secure the base portion ofthe toilet to the flange.
 5. The flange of claim 4, wherein an externalsurface of the at least one mounting bolt is threaded.
 6. The flange ofclaim 1, wherein the surface is an existing toilet mounting flangemounted to a floor and wherein the at least one aperture is adapted toreceive a connector for attaching the flange to the existing toiletmounting flange and the floor.
 7. The flange of claim 6 wherein thefloor is proximate to at least one wall of a room, the flange furthercomprising one or more alignment indicia disposed on the annular ring tofacilitate positioning of the annular ring such that the toilet ismounted in a predetermined angular orientation relative to the at leastone wall.
 8. A repair flange adapted to overlay a broken toilet flangeand to secure a toilet to a floor, the broken toilet flange positionedbetween the toilet and the floor, the toilet including a base portiondefining at least one mounting aperture, the repair flange comprising:an annular ring having one or more mounting tabs that each define a tabaperture, wherein each tab aperture is adapted to receive a connectorfor attaching the repair flange to a floor; and at least one mountingbolt rigidly and permanently affixed to the annular ring, the at leastone mounting bolt extending upwardly from the annular ring and beingadapted to pass through at least one mounting aperture of the toilet. 9.The repair flange of claim 8, wherein the tab apertures are attached toan outside periphery of the annular ring.
 10. The repair flange of claim8, the broken toilet flange having an annular ring that defines one ormore apertures, the repair flange further defining one or more aperturesthat coincide with the one or more apertures of the broken toiletflange.
 11. The repair flange of claim 8, further comprising at leastone one-piece toilet bowl mounting cap, the toilet bowl mounting capadapted to be mated with the at least one mounting bolt to secure thebase portion of the toilet to the flange.
 12. The flange of claim 11,wherein an external surface of the at least one mounting bolt isthreaded and wherein an internal surface of the one-piece toilet bowlmounting cap is threaded.
 13. A flange for extending a thickness of anexisting toilet mounting flange, the existing toilet mounting flangepositioned between a base portion of a toilet and a floor, the flangecomprising: an annular ring defining at least one aperture adapted toreceive a connector for attaching the flange to the existing toiletmounting flange and the floor; and at least one mounting bolt rigidlyand permanently affixed to the annular ring, the at least one mountingbolt extending upwardly from the annular ring and being adapted to passthrough at least one mounting aperture of the toilet.
 14. The flange ofclaim 13, further comprising at least one one-piece toilet bowl mountingcap, the toilet bowl mounting cap adapted to be mated with the at leastone mounting bolt to secure the base portion of the toilet to theflange.
 15. The flange of claim 14, wherein an external surface of theat least one mounting bolt is threaded and wherein an internal surfaceof the one-piece toilet bowl mounting cap is threaded.